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1. NOTE Cycle will not start if baler is not ready amp hopper door is closed BALER READY The baler must be ready for the CYCLE START push button to be operative If the message PRESS CYCLE START is not displayed then the baler is not ready INITIAL STARTING CONDITIONS BALER NOT READY If the baler is not ready check the display on the OPERATOR S CONSOLE to see which of the following initial conditions have not been met The automatic cycle cannot be started unless all of these conditions are met 1 1 RAM retracted 2 2 RAM retracted 3 GATE closed 4 SIDE HOPPER down and GUARD DOOR closed NOTE If abbreviations used are unfamiliar see ABBREVIATIONS If any of the initial conditions 1 thru 4 have not been met turn the selector switch to the HAND position restart pumps Cif necessary and bring rams to their proper starting positions then repeat the initial steps for starting the auto cycle Optional feature may not apply if not furnished by Galland Henning Nopak 27 COMPLETE AUTOMATIC SEQUENCE CYCLE ON STARTED The initial automatic cycle begins when the baler is ready and the CYCLE START button is depressed and held until the 1 Ram begins to advance 1ST COMPRESSION STAGE As soon as the CYLCE START button is depressed SOL IRA is energized and the 1 Ram will advance As the 1 Ram advances it will de actuate switch LSIRR and the message 1 RAM AD
2. VENT VALVES The term vent characterizes an application of a directional valve which is used either to exhaust vent or block the port or chamber of yet another valve such as a relief valve The loading and unloading of a pump is usually accomplished through the combined action of a vent valve and a relief valve PRESSURE CONTROL VALVES limit the pump and circuit pressures and reduce pressure spikes A brief description of each pressure control valve on this machine can be found under VALVE UNLOADING RELIEF III 10 VALVE TERMINOLOGY The following terms apply specifically to valves used on this machine INFINITE POSITIONING This term characterizes a type of valve in which the piston or spool is free to assume any of an infinite number of possible positions within the valve body between fully open and fully closed A typical application would be a pressure relief valve where the piston s position varies with the degree of relief required FINITE POSITIONS This term characterizes a valve in which the piston or spool can as sume one of only a limited number of predetermined positions usually two or three The interconnected ports are either fully open or fully closed NEUTRAL normal POSITION This term refers to the position the piston or spool will assume when at rest or idle not being acted upon by a control signal THREE POSITION 3 position VALVE is a valve in which the piston spool can assume one
3. Check motor connections 1 Check line from reservoir to pump 2 Be sure filters or strainers are not clogged 1 Check oil level in reservoir Intake line must be be 1 If air is going through pump it will be noisy Pour oil over suspected joints if noise stops you have found the leak 1 Check recommended speed by manufacturer 2 Check driving motor 1 If oil is too heavy pump cannot pick up prime 2 Drain and fill with oil of the right viscosity 1 Disassemble pump inspect parts broken shaft and follow manufacturer s loose couplings recommended to the letter IV 12 TROUBLE SHOOTING TIPS cont OVERHEATING IN SYSTEM CAUSE OIL VISCOSITY TOO HIGH INTERNAL LEAKAGE TOO HIGH EXCESSIVE DISCHARGE PRESSURE POORLY FITTED PUMP UNITS OIL COOLER CLOGGED LOW OIL LEVEL IV e 15 ACTION 1 Check oil recommendations 1 Oil viscosity may be too low Check oil recommendations 2 Check wear and loose packings 3 Check temperature of oil 1 Check oil viscosity recommendations 2 Check relief valve setting 1 Poorly fitted parts may cause undue friction Be sure all parts are in alignment 1 If oil cooler passages are clogged try blowing out with solvents 1 If oil supply is low less oil will be available to carry away just as much heat This will cause a rise in oil temperature Be sure it is up to proper level TROUBLE SHOOTING TIPS cont LOW PRESSURE IN SYSTEM AND ERRATI
4. 2nd compression stage of bale making MAIN STAGE See Solenoid Controlled Pilot Operated Valves under VALVE CONTROL PILOT STAGE See Solenoid Controlled Pilot Operated Valves under VALVE CONTROL HI 11 VALVE TERMINOLOGY cont BALANCED PISTON This term characterizes a type of relief valve in which the valve s main piston divides the valve bore into two distinct chambers an upper or control cham ber and a lower or load chamber During operation the hydraulic force acting on the control side of the piston equals or balances the force acting on the load side until a pre set pressure limit is reached When this limit is reached and or exceeded the control chamber is ventilated i e pressure is relieved and the resulting imbalance causes the pis ton to shift leave its normal position III 12 VALVES RELIEF This is a direct acting valve that limits the maximum operating pressure in the system When the system pressure reaches the relief valve setting the valve s piston shifts to allow excess pump out put to be vented directly to the tank line NOTE This system uses a pressure compensated variable displacement pump which reduces its own output as the pressure reaches the compensator s setting The relief valve is a backup for the pressure compensator on the pump and should only open momentarily to relieve any pressure spike in the system The relief valve setting should be approximately 200 ps
5. A Pressing both push buttons simultaneously and for 1O seconds locks or unlocks the switch for setting the control points B Pressing the Mode Enter push button steps the switch through its different functions When the desired parameter is reached pressing the Set push button will display current setting of that parameter If the switch is unlocked this value can be changed by pressing and holding the Set push button for 5 seconds and the setting will flash and then start stepping through its range Releasing and pressing the button now will allow you to manually step the switch through the range When the desired setting is reached pressing the Mode Enter button sets the switch to the new setting and return the switch to the function display When the maximum setting is reached it will start over looping back to the lowest setting III 16 LEVEL TEMPERATURE SWITCH cont C When the switch is in the function mode if no switches are pushed for 5 seconds the switch will return to the operating mode D The switch functions are as follows switch 1 on set point switch 1 off set point dS1 delay of switch 1 on set point OUT output of switch 1 see operating instructions OP see specification sheet see operating instructions MEDI see operating instructions OFS see operating instructions Repeat for switches 2 3 amp 4 E Switch should be locked after set points have bee
6. SUBJECT WARNING LABELS The following warning labels have been affixed to this baler and the definitions given below A ELECTRICAL HAZARD VOLTAGES EXCEED 30V OR 60V DC DANGER CRUSH HAZARD FROM ABOVE READ MANUAL BEFORE OPERATING MACHINERY 6 LOCKOUT IN DE ENERGIZED STATE BEFORE SERVICING WEAR HEARING PROTECTION LIFT POINT SUBJECT WARNING LABELS cont SLIP HAZARD DO NOT OPERATE WITHOUT GUARDS IN PLACE CRUSH HAZARD FROM RIGHT CRUSH HAZARD FROM BOTH SIDES CRUSH HAZARD FROM ABOVE REPLACE FUSE WITH ONE OF PROPER RATING SUBJECT WARNING LABELS cont O AUTOMATIC CYCLE CYCLE START MASTER RESET EMERGENCY STOP POWER ON GROUND PHYSICAL EARTH DANGER DO NOT REMOVE COVER OR OBLITERATE THESE LABELS FAILURE TO COMPLY WITH THESE WARNINGS CAN LEAD TO SERIOUS INJURY OR DEATH SECTION I INTRODUCTION TABLE OF CONTENTS PREFACE HOW TO USE THIS MANUAL INSTALLATION BLUEPRINTS OIL RECOMMENDATIONS ABBREVIATIONS GENERAL SPECIFICATIONS DRAWING LIST TABLE PREFACE This manual kit consists of five 5 sections of text each having its own table of contents as well as a group of blueprints See Drawing List vendor bulletins and a copy of the logic program printout These sections are Introduction which contains a description of text format and use numerous data tables and illustrations for which there are coded references throu
7. Be sure the pump housing is filled with oil by discounting the drain line form the pump housing and filling with clean new oil The pump should prime itself immediately if the following conditions exist A Pump is rotating in the proper direction B All pump inlet connections are absolutely air tight C Oil level is adequate and is of the proper type and viscosity D There is no load on pressure outlet port of pump when started A pump should not be started against a load or a closed centered valve START UP PROCEDURES FOR HYDRAULIC SYSTEMS cont If a pump does not prime jog start stop it intermittently It may be necessary to loosen downstream pressure side fitting to purge trapped air WARNING Do not run a pump which will not prime or is cavitating If the pump is noisy producing a gurgling or crackling sound air could be mixed with the oil For possible cause and remedy see TROUBLE SHOOTING TIPS NOISY PUMP in the MAINTENANCE section 5 Set all relief valve pressure limit RV1 2 600 psi 180 Bar NOTE For detailed instructions on setting relief valves look under VALVES UNLOADING RELIEF in this section 6 With machine in the manual mode mode selector switch in the hand position fully extend and retract all cylinders several times This will fill the cylinders and piping with hydraulic oil NOTE It may be necessary to adjust limit switch positions to achieve the desired travel of each cylinder For limit
8. PLUMBING SAFETY GUARD ASSEMBLY SECOND 2ND COMPRESSION CYLINDER SECOND 2ND COMPRESSION LIMIT SWITCH SIDE HOPPER LIMIT SWITCH ASSEMBLY SOLENOID IDENTIFICATION LOCATION MODEL 16DC SERIAL H 2026 DRAWING NO LP 25 D 12119 X 56 C 174 DC16 D 19549E16 C 5171SK B 173 DCI6 C 195 DC16 C 12O23 J1O C 11764 X34 D 172 DC16 D 1792 J16 D 19569Y16 B 15685Y12 SEE 12 DL D 11793 J16 D 18850 J16 D 18867 J16 D 19551J16 B 5172 SK A D 172 DCI6 N A SEE 12 DL SECTION II OPERATION TABLE OF CONTENTS PAGE OPERATOR ORIENTATION 11 1 PROCEDURES SAFETY PRECAUTIONS 1 1 amp 2 CONTROLS 3 MANUAL MODE 1 4 AUTOMATIC MODE Il 5 amp 6 COMPLETE AUTOMATIC SQUENCE II 7 thru 9 BULK HOPPER OPERATION II 1O SIDE HOPPER OPERATION 1 11 ALARM SYSTEM 1 12 ABNORMAL BALES Il 13 BALE DENSITY 1 14 CHANGING THE NUMBER IST COMPRESS CYCLES 11 14 OPERATOR ORIENTATION ORIENTATION Use the General Arrangement drawing to gain visual recognition of the following principal working parts GATE 1 CYLINDER 2 CYLINDER BULK FEED HOPPER SIDE HOPPER To find more detail on these components refer to the drawing list in Section I APPLICATION This baler has been designed to perform a specific baling process i e baling skeletons trim cups and can bodies Baling of any other materials will be considered a non standard application The proper order of the process begins with measuring and loading see B
9. element SOLENOID OPERATED The valve element is shifted when an electromagnetic force produced by an energized solenoid acts on the valve element via an armature and pushrod device The electric current is controlled by a pressure switch limit switch control relay or a PLC The solenoid meth od of actuation is used when only a small amount of force is needed to shift the valve See MAN UALLY SHIFTING A VALVE PILOT OPERATED The valve element is shifted when a hydraulic force or lack of it acts on the valve element either directly or via a pilot piston Pilot pressure is used when shifting the valve element requires more force than can be provided by the solenoid alone SOLENOID CONTROLLED PILOT OPERATED VALVES AII pilot operated directional valves on this machine are two stage valves a main stage and a pilot stage The pilot state is a small solenoid operated valve which supplies the pilot pressure necessary to shift the valve element of the main stage SOLENOID CONTROLLED RELIEF VALVES which load and unload the pumps are arranged in a similar fashion a main relief stage and a pilot stage Energizing the solenoid results in pressuriz ing the pilot section which enables the pump to be loaded When the solenoid is de energized the pilot section is vented to tank unloading the main stage DIRECT ACTING Positioning of the valve element is determined by the amount of pressure within the valve body at either the outlet or inlet port
10. of only three possible positions which would be as follows assuming the spool axis is oriented horizontally 1 SHIFTED energized left 2 UNSHIFTED neutral position 3 SHIFTED energized right TWO POSITION 2 position VALVE is a valve in which the spool can assume one of only two possible positions Either of which may be the normal or unshifted position FOUR WAY 4 way VALVE isatype of directional valve which alternately pressurizes and exhausts two of its ports simultaneously while one port serves as an inlet for pres surized flow the other port serves as an outlet for discharge flow and vice versa THREE WAY 3 way VALVE isa type of directional valve which alternately pressurizes and exhausts a single port OPEN CENTER CROSSOVER This term refers to a type of directional control valve in which pressure in the working lines is relieved while the spool assumes its neutral position CLOSED CENTER CROSSOVER This term refers to a type of directional control valve in which pressure in the working lines is captured while the spool assumes and remains in its neutral position A ram controlled by a valve of this type will resist being forced from its desired position as the valve shifts This is a feature of the 1 Ram directional valve on 16 DC balers Its use eliminates the need for a pilot operated check valve at the cylinder s blind end without which the 1 Ram would slip from its fully forward position during the
11. or by the differential pressure between them PILOT PRESSURE Internally or externally supplied pressure controlled by the pilot section used to shift the main valve element Externally supplied pilot pressure is supplied to the valve through the X port shown on the hydraulic diagram Similarly an external pilot drain is shown as the Y port MANUALLY SHIFTING A VALVE AII the solenoid operated valve on this machine can be manually overridden by locating the plunger in the appropriate end of the solenoid housing and depress ing the plunger with a suitable tool CAUTION Don t override a valve solenoid without first fully evaluating the consequences Be sure to alert any personnel in the machine s immediate vicinity Ill 9 BASIC VALVE TYPES As mentioned earlier each type of valve is designed for a particular application However valves can be identified as being one of the following basic types DIRECTIONAL CONTROL VALVES These valves start stop and direct the flow They control the loading and unloading of pumps via solenoid controlled relief valve and the extension and retraction of cylinders A brief description of each directional valve on this machine can be found under VALVE DIRECTIONAL Each solenoid controlled pilot operat ed directional valve is also designated in these applications by the solenoid s that oper ate it CHECK VALVES are a type of directional valve which permit flow in one direction only
12. plunger in the appropriate end of the solenoid housing and depress it with a suitable tool The hex head bolt on the manifold side of the pump is the compensator screw and adjusts the maximum pressure of the pump the long threaded rod on the opposite side of the compensator is the maximum volume stop III 15 PRESSURE SWITCHES The purpose of a pressure switch is to translate a hydraulic signal into an electrical signal This is achieved by the interaction of a small hydraulic actuator directly with an electrical switch The slight motion of the actuator which results in an open or closed electrical element occurs only when pressure rises above or falls below the selected operating point 5 1 BALE MADE Operating point 2 400 psi 165 bar Reset point 2200 psi 150 bar FUNCTION To signal that a bale has been made which halts 2 cylinder s forward movement PS 2 BALE EJECT Operating point 1100 psi 75 bar Reset point 950 psi 65 bar FUNCTION To signal the baler that the bale has been ejected PS 3 RECYCLE 1 CYLINDER Operating point 900 psi 62 bar Reset point 800 psi 55 bar FUNCTION To signal the baler the maximum amount of material is in the baling chamber and that it to finish the baling cycle 5 4 1 RAM FORWARD HOLD Operating point 1200 psi 83 Bar PRESSURE SWITCH Typical CONTROL method of actuation Hydraulic fluid piped from the pump discharge circuit to the switc
13. program OPTIMUM BALE SIZE must be determined by user but in no case should a load be so large as to prevent full extension of the 1 Ram during the Ist Compression Stage Changing the nuber of 1st Compress Cylinder Cycles The baler is programmed to cycle the 1st Compression Cylinder several times before forming the bale The number of these cycles can be changed from the operator s station without having to access the program in the PLC The method for doing this is as follows 1 With the baler s power on turn the key switch to the OFF position 2 Go to the MAINTENANCE screen on the HMI 3 Press and hold the F8 ENTER COUNT pushbutton for more than 5 seconds 4 After releasing the button MAINT should appear in the mode display in upper right corner 5 Press the F3 CYCLES PER BALE to the ADVANCE the count number Note In this mode the display updates very slowly It may take several seconds before the number changes 6 Each time the F3 CYCLES PER BALE button is pushed the count increases by 1 until it reaches 9 and then returns to 1 7 Switching the key switch to the HAND or AUTO position will exit this mode II 15 SECTION III MACHINE SYSTEM TABLE OF CONTENTS HYDRAULICS PRINCIPLES amp TERMINOLOGY PNEUMATIC PRINCIPLES START UP PROCEDURES FOR HYDRAULIC SYSTEMS PUMP TERMINOLOGY PUMP DATA VALVES OPERATION amp CONTROL BASIC VALVE TYPES VALVE TERMINOLOGY VALVES RELIEF PRESSUR
14. three basic groups of dynamic devices They are 1 PUMPS which transform the power from the primary source such as electric motor to hydraulic force by generating an unyielding flow of hydraulic fluid 2 VALVES which control the hydraulic action by determining the direction of the flow of the hydraulic fluid 3 ACTUATORS such as cylinders which convert hydraulic force into useful work by absorbing the flow of hydraulic fluid HYDRAULIC CIRCUITS are formed when these static and dynamic devices are coupled together to perform work Separate tasks or operations require and are performed by separate circuits THE HYDRAULIC SYSTEM consists of many individual hydraulic circuits Several individual circuits may share a single pump or flow path or other device provided it does not interfere with the func tion of any single circuit HYDRAULIC SYSTEM CONTROL The control of the system as a whole is accomplished by con trolling the individual components Some components are controlled by electrical signals while others are controlled by hydraulic pressure For particular component control explanations see the appropriate component description on the following pages PRESSURE REGULATION Pressure is controlled by directing the flow of hydraulic fluid from re gions of high resistance to regions of low resistance If the flow is continuously forced into a space which can no longer expand pressure will reach a dangerous level and component
15. 7DCS 5ODC 40DCS 60DC 80DC is in conformity with the applicable requirements of the following documents Ref No Title EN 55011 2009 A1 2010 Industrial scientific and medical equipment Radio frequency disturbance characteristics Limits and methods of measurement EN 61000 6 2 2005 Electromagnetic Compatibility EMC Part 6 2 General Standards Immunity for ndustrial Environment EN 61000 6 4 2007 Electromagnetic Compatibility EMC Part 6 4 General Standards Generic standards Emission standards for industrial environments EN ISO 12100 2010 Safety of Machinery General principles for design Risk assessment and risk reduction ISO 12100 2010 I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications and is in accordance with the requirements of the Directive s Name Bart Mitchell Position President Done at GALLAND HENNING NOPAK INC 1025 South 40th Street West Milwaukee WI 53215 On March 31 2014 Document Ref No SFIIOIBAT GHN GALLAND ci HENNING NOPAK 10179 S 57th Street Franklin WI 53132 USA 414 645 6000 www nopak com
16. C ACTION CAUSE VALVES PISTON ETC STICKING OR BINDING CYLINDERS NOT OPERATING PROPERLY RELIEF VALVE RELIEF VALVE SETTING TOO LOW RELIEF VALVE STUCK OPEN LEAK IN SYSTEM BROKEN WORN OR STUCK ACTION 1 Check for mechanical deficiencies such as misalignment of a shaft worn bearings etc Replace worn parts 2 Check oil for signs of dirt oil sludge varnishes etc caused by oil deterioration Clean parts and replace oil 1 Re adjust relief valve or unloading valve setting 2 Check for worn pump 3 Check for sticking valves 4 4 way valve not shifting 5 Leak in system check piping 6 Leak inside cylinder check piston assembly replace 7 Low oil level in reservoir 8 Rod end packing too tight A LARGE PISTON STUCK REPLACE OPEN B SMALL HOLE IN LARGE PISTON PLUGGED C PISTON OR VALVE SEAT IN COVER DAMAGED D DIRT BETWEEN PISTON AND HEAD E RELIEF VALVE CHATTER 1 Disassemble valve and clean parts Replace damaged and worn parts 1 Block discharge line beyond relief valve and check line pressure with pressure gauge 2 Re adjust pressure setting or valve with new gauge 1 Disassemble valve and clean 2 Stuck valve may indicate dirty oil or deteriorated oil Change if necessary 1 Check all tubing and piping for leaks 1 Install pressure gauge and block System just beyond relief valve If no pressure is developed and relief valve is alright look for mechanical tro
17. E SWITCHES LIMIT SWITCHES PAGE 1 2 11 2 11 5 amp 4 11 5 amp 6 1 7 1 8 amp 9 11 10 11 1 amp 12 Il 15 11 14 amp 15 11 16 thru 19 HYDRAULIC PRINCIPLES amp TERMINOLOGY HYDRAULIC FORCE When a non compressible fluid such as hydraulic oil is forced into a closed space it exerts the same force on all surfaces it contacts This force is called pressure and it is measured in pounds per square inch abbreviated psi In this manual pressure is given in both psi and Bar HYDRAULIC PRESSURE Will occur whenever there is resistance also called the load to the flow of the fluid Pressure in a closed space into which a flow is continuously forced will increase con tinuously and without limit until the space expands or until the flow ceases or escapes HYDRAULIC ACTION Will cause the weakest surface to move first The motion will occur when the total hydraulic force exceeds the resistance of the surface on which it acts Total hydraulic force is usually measures in pounds or tons and it is the product of the pressure psi multiplied by the area square inches of the surface on which it acts HYDRAULIC COMPONENTS The hydraulic system consist of static and dynamic mechanical devic es which have been designed to make use of hydraulic principles STATIC DEVICES have NO moving parts They include hoses pipes fittings manifolds tanks etc DYNAMIC DEVICES have moving parts There are
18. ETY PROCEDURES as outlined in the OPERATION SECTION The following steps should be taken whenever a new repaired or previously idle hydraulic system is started 1 Be sure that all exposed cylinder rods are free of rust and abrasions especially if machine has been idle for prolonged periods Any rust or abrasion should be removed with emery cloth and oil and wiped clean 2 Check the oil level of the reservoir For system capacity See BALER SPECIFICATIONS Oil level should be within limits indicated on the sight gauge Low oil levels will hinder heat dissipation and permit excessive condensation in the tank Pump damage may also occur NOTE For oil type and specification see OIL RECOMMENDATIONS 3 Check for proper direction of pump rotation If the direction of rotation is opposite of that which is desired change motor wiring accordingly To determine the proper direction of rotation examine the pump cover housing opposite the shaft end and locate the rotational arrow This arrow indicates the proper direction of rotation as seen from the viewer s position IMPORTANT NOTE Pumps are normally specified having right hand clockwise rotation as viewed from the shaft end However certain applications require left hand rotation Such as when pumps are mounted at both ends of the prime mover motor Left hand pumps are identified by an L stamped on the model identification tag located on the pump cover housing I 3 4
19. GALLAND HENNING High Density Baling Solutions Operations Manual Model 16DC GALLAND HENNING NOPAK INC OPERATION amp MAINTENANCE MANUAL FOR SERIES DC amp DCS BALING PRESSES MODEL 16DC BALING PRESS PREPARED FOR BAGPAK Polska Sp z o o 03 285 Warszawa ul Kondratowicza 18 183 Zaklad w Stalowej Woli 57 450 Stalowa us Kwiatkowskiego 1 POLSK CUSTOMER P O NUMBER BP2014 GHOI GH SERIAL NUMBER H 2026 CONTRACT NO 1470116 MANUFACTURED BY GALLAND HENNING NOPAK INC 1025 SOUTH 40TH STREET WEST MILWAUKEE WI 53215 USA 16DC BALER s n H 2026 400V 5OHZ 3 43 FLA LARGEST MOTOR 25HP 34 FLA DOCUMENT NUMBER D 19549 E16 YEAR OF CONSTRUCTION 2014 IT IS THE RESPONSIBILITY OF THE INSTALLER OF THIS EQUIPMENT TO PROVIDE SUITABLE SUPPLY WIRING CONSULT THE MANUFACTURERS IDENTIFICATION LABEL ON THE MACHINE TO DETERMINE VOLTAGE AND AMPERAGE REQUIREMENTS WHEN DETERMINING THE WIRING SIZE Cm The supply wiring must be approved for use in the country in which this equipment is installed or bear the lt HAR gt mark A separate bi color ground wire that is green in color with a yellow stripe must be run in the hard pipe conduit along with the supply wiring The conduit must be grounded in accordance with the National wiring rules and regulations of the country where installed The fittings installed where the service wiring enters the body of the panel must not reduce the panel Ingress Protection rating
20. N PUMP STUCK PUMP VANES VALVES FILTER OR STRAINER TOO DIRTY PUMP OUT OF LINE WITH MOTOR PUMP PICKING UP AIR AROUND SHAFT OR HEAD PACKING EXCESSIVE PRESSURE IV 1 ACTION 1 Check oil level intake must be below surface of oil 2 Check pipe and tubing connections 1 Check oil level and return line position 2 If oil level is low or return line to reservoir is installed above oil level air bubbles will form in oil in reservoir 1 Restricted intake line 2 Plugged air vent in reservoir 3 Check strainers in intake line 4 Oil viscosity too high 5 Pump overheated 1 See vendor overhaul manual 2 Check gaskets and packings 3 Replace worn parts 4 Check oil may be dirty 1 Use solvent to clean parts and dry thoroughly before reassembling 2 If stuck due to corrosion and rust replace parts 3 Check for dirty oil 1 Clean filter or strainer 2 Be sure original filter has not been replaced by one of smaller capacity 1 Check alignment Misalignment may be caused by temperature variation 1 Replace packings 2 Grease pump fitting 1 Check relief valve setting 2 Check for line restriction TROUBLE SHOOTING TIPS cont PUMP NOT DELIVERING OIL CAUSE PUMP SHAFT TURNING IN WRONG DIRECTION INTAKE CLOGGED LOW OIL LEVEL low level of oil AIR LEAK IN INTAKE PUMP SHAFT SPEED TOO LOW OIL TOO HEAVY MECHANICAL TROUBLE WORN PUMP ACTION 1 Shut down immediately
21. OBSERVE ALL NECESSARY PRECAUTIONS BEFORE REACHING INTO THE BALING CHAMBER OVERSIZED BALES An oversize bale shall mean any bale that is large enough to cause the baler to stall In the event an oversize bale is formed it will be necessary to turn the mode selector switch to the HAND position restart the pump open the gate and determine if the bale will fit through throat of the gate before attempting to push it out with the 2 Ram WARNING Do not attempt to force an oversize bale through the throat of the gate Serious damage to the baler could result Oversized bales as such must be removed through the top of the baler by other means II 14 BALE DENSITY Bale density should not vary noticeably provided the scrap is uniform in characteristics and the maximum working pressure is properly maintained See PRESSURE SWITCHES PSI BALE SIZE REGULATING Two of the bales three dimensions are fixed and are approximately equal to the height and width of the 42 Ramhead s face plate The fixed dimensions are determined by the confines of the baling chamber with the 1 Ram fully forward The third 3rd dimension i e the length of the bale is variable Under normal circumstances the length of a bale will vary only if the weight or characteristics of the loads vary i e the more loads the bigger the bale To regulate the size of a bale the number of bulk hopper dumps must be changed This can only be done within the logic
22. RECAUTIONS to protect personnel and equipment when baler or baler components are being operated in a non routine manner 1 2 PROCEDURES SAFETY PRECAUTIONS cont TROUBLE SHOOTING OR TESTING should be performed only by individuals who are familiar with the systems that control the operation of this machine LOCK AIR SUPPLY IN OFF POSITION before working on the pneumatic system hopper door or hopper diverter gate Optional feature may not apply if not furnished by Galland Henning Nopak CONTROLS MODE OPTIONS This baler is designed for two modes of operation Manual and Automatic The Manual Mode is primarily for servicing and readying the baler for automatic use The Auto Mode is the normal mode for baling Automatic loading via the BULK HOPPER permits continuous cycling Use of the side hopper will interrupt bulk hopper operation Baler must be cycled to return to continuous operation MODE CONTROLS All of the operator s controls are located on the OPERATOR S CONSOLE See Console Guide Some controls are operative only in manual while others are operative only in auto The baler must be powered up before either set of mode controls is operative Side hopper control is operative in either mode BALER POWER UP for operation in either mode is accomplished by satisfying the following conditions 1 EMERGENCY STOP push buttons must be pulled out to engage control power Control power and machine proce
23. RETURN HOME When the Eject Stage ends the rams will return to their initial starting positions in the following order 1 The Z2 Ram retracts SOL 2RR is energized until it actuates LS2RR 2 The Gate closed SOL GC is Energized until it actuates LSGC 3 The 1 Ram retracts SOL 1RR is energized until it actuates LSTRR NOTE Under certain circumstances the newly formed bale may cling to the 42 Ramhead and be pulled back into the baling chamber as the 42 Ram retracts SEE ABNORMAL BALES STICKERS Page 11 1 DANGER DO NOT ATTEMPT TO FREE THE BALE DURING THE AUTO CYCLE FIRST TURN THE MODE SELECTOR SWITCH TO THE HAND POSITION THEN REMOVE BALE SEE SAFETY PRECAUTIONS CYCLE ENDS The auto cycle ends when the initial starting conditions are satisfied BALER READY again CYCLED IN AUTO All of the cylinders will be in their starting positions at this time DIVERT TO BALER The automatic Bulk Hopper will divert to baler if not already in BALER POSITION Il 9 COMPLETE AUTOMATIC SEQUENCE cont SUBSEQUENT CYCLES Once a CYCLED IN AUTO condition is achieved the AUTO START BALER ONLINE push button is depressed and each subsequent cycle will be initiated automatically when the BULK HOPPER completes its normal function The baler will continue to operate in this manner until it is stopped or the mode is changed by the operator NOTE Subsequent cycles may be initiated manually at
24. VANCING will be displayed If the pressure to advance 1 Ram is below approximately 800 psi 55 Bar the counterbalance allows the 1 Ram to advance at high speed and reduced force If the pressure raises above approximately 800 psi 55 Bar the 1 Ram will advance at a slower speed but at full force The 1 Ram will continue to advance until it actuates switch LSIRF SOL TRA is de energized at which time the Ist compression stage ends The RAM ADVANCING message will stay on until 42 Ram starts advancing NOTE If the baling chamber is loaded with to much scrap the force required to compress the scrap will exceed the capability of the hydraulic system and the 1 RAM will not reach its forward position limit switch LSIRF and the baler will stall during the 1st compression stage Displaying 1 RAM STALLED DANGER DO NOT ATTEMPT TO FORCE COMPLETION OF THE Ist COMPRESSION STAGE BY INCREASING THE HYDRAULIC PRESSURE LIMIT OR BY MANUALLY ACTUATING THE tl RAM FORWARD LIMIT SWITCH LSIRF AS EITHER OF THESE PRACTICES COULD RESULT IN SERIOUS DAMAGE TO THE BALER AS WELL AS CREATE POTENTIAL SAFETY HAZARDS NOTE In order to obtain a larger size bale the automatic operation is provided with a counter that will cause the 1st compression ram to return to its starting position to gather more scrap before finishing the baling cycle If the pressure on the 1 Ram is above approximately 800 psi 55 Bar when the ram reaches the LSIRAF th
25. Work on or about the machine must never be done in a hasty or disorderly manner When two or more personnel are working on or about the baler each individual must be aware of the location and activity of all others present Stay absolutely clear of all pinch shear and press points while power is on Do not attempt to circumvent safety guards or safety interlocks Hearing protection must be worn when working on or near this machine Use a step ladder to access components that are out of reach Do not climb on this machine Immediately clean any oil that may have accumulated on the floor failure to do so may create a slipping hazard In addition to the above precautions ABSOLUTELY NO ONE should reach or climb into the baling chamber either through the GUARD DOOR or the GATE while the pumping unit is operating LOCK MAIN DISCONNECT IN OFF POSITION before performing work inside the baling chamber or on or about other pinch press and shear points or moving parts PROVIDE POSITIVE SUPPORT for SIDE HOPPER optional and GATE if they are to be worked on or about while in the raised position MAINTENANCE PERSONNEL AND ELECTRICIANS who are not familiar with normal baler operation should not attempt to trouble shoot problems unless an experienced Operator is present THINK FIRST Do not manually override directional valves control relays or switches without fully evaluating the consequences first TAKE P
26. al type limit switch is actuated when its lever is tripped by a moving part of the machine 2 Proximity sensor switch is activated when a metal target enters the sensor s field NOTE Mechanical type limit switches are to be positioned so that during use their actuators are not forced beyond their allowable over travel Otherwise damage to the switch will result Proximity sensors are positioned within 34 of target to activate Most limit switches have both a normally open N O and a normally closed N C contact set When the limit switch is activated the N O contacts will be held closed and the N C contacts will be held open For additional information on these switches see the appropriate vendor bulletins LSGC LIMIT SWITCH GATE CLOSED OPERATION FUNCTION POSITION The N O contacts switch will close when the gate is fully closed and will remain closed until the gate begins to open See Electrical diagram and or program The switch must be positioned so that it will stop the closing gate before it contacts the bottom liner plate Allow a clearance of approximately 1 16 inch LSGO LIMIT SWITCH GATE OPEN OPERATION FUNCTION POSITION III 19 The N O contacts will close when the gate is fully open and reopens when the gate begins to close See Electrical diagram and or program The switch must be positioned so that the switch actuates and the gate will stop opening when th
27. being designed and used for a particular application The type of valve and its most common application is implied by the valve s common name a pressure relief valve is used to relieve excessive pressure With a little experience it is possible to visually recognize valve types by their external features as most valves of a similar type resemble each other in appearance Recognition of valve types and knowledge of their typical applications are indispensable tools to those responsible for maintaining this equipment Although there are several different types of valves used on this machine each valve is alike in the sense that it controls the direction and or volume of flow using a piston or spool The piston or spool either opens and or blocks passages between the valve s ports as it assumes different positions within the bore of the valve body Control of the piston or spool position within the valve results in controlling the direction force and in some cases the speed of the ram or other actuator which the valve is said to control There are several methods for controlling the position of a valve s piston or spool most of which are discussed briefly under VALVE CONTROL Ill 8 VALVE CONTROL Valve control can be accomplished by a mechanical electrical or hydraulic actuating force which is commonly referred to as a signal For the sake of simplicity the valve s piston or spool shall be referred to as the valve
28. chine is the product of many years of specialization in hydraulic engineering appli cation and scrap processing know how The simplicity and balance of its design assures maximum possible life of each component while providing continuous and dependable service Maximum utilization of the machine however can be achieved only if the user designs and implements from the moment of start up a maintenance program which provides lubri cation cleaning and inspection adjustment on a regular basis Failure to provide this kind of maintenance can result in rapid and abnormal deterioration of the machine s load bearing components In turn this may unexpectedly cause a partial or even total machine disablement To avoid this likelihood use the following mainte nance guideline to establish a program tailored to the environment of your machine and the frequency of its use MAINTENANCE GUIDELINES Performing routine maintenance in accordance with the following guidelines will require intermittent machine operation to provide easy access to all service areas Because the machine is not invulnerable to abuse which may occur at the hand of an inexperienced op erator we recommend the maintenance be performed by or with the assistance of some one familiar with its operation either through this manual or other experience INSPECTION PROCEDURE LUBRICATION A good grade of multipurpose grease will suffice for those points with grease fitting and
29. e cycle will be completed the bale will be ejected and the counter will be reset The counter is accessible through the PLC program only 2ND COMPRESSION STAGE The 2nd compression stage begins when the 1st Compression Stage ends At this time the 2 Ram will advance SOL2F is energized As the 42 Ram advances it deactivates switch LS2R and the message 42 RAM ADVANCING will be displayed The 42 Ram will continue to advance until bale made pressure 2400 psi 165 Bar is reached at which time the BALE MADE message is displayed The 2 Ram stops advancing and the 2nd compression stage ends 2 RAM position is variable BALE MADE The BALE MADE message will be displayed upon completion of the 2nd compression stage PS1 actuated When the BALE MADE message is displayed the baler has completed the bale making stages and is ready to begin the decompression stage NOTE From the viewpoint of the control circuit logic the bale is considered to be made only during the 2nd Compression Stage If the box is overcharged and the baler is stalled in the 1st Compression Stage the BALE MADE message would not be displayed even though a bale had been formed The automatic baling sequence will be canceled and the oversized bale will have to be removed manually See Abnormal Bales Oversized Il 8 COMPLETE AUTOMATIC SEQUENCE cont DECOMPRESSION Decompression removes the load imposed on the working parts of the system duri
30. e gate cylinder rod is within 1 8 inch of the end of its fully retracted position stroke Bottom of gate should clear the 42 Ram head by approximately 1 2 inch LIMIT SWITCHES cont LSIRR LIMIT SWITCH 1 RAM RETRACTED back OPERATION FUNCTION POSITION The N O contacts will close when the 1 Ram is fully retracted when the target trolley cam on the end of the trolley rod trips the switch lever See Electrical diagram and or program The switch must be positioned so that it will actuate and stop reversing the 1 Ram just as the face of the ram head recedes from lower inside edge of the 1 wiper the ram head should not protrude into the box LSIAF LIMIT SWITCH 1 RAM ALMOST FORWARD OPERATION FUNCTION POSITION The contacts will close when the 1 ram is approximately 4 before the LSIRF This is when the To energize an input signal to the PLC when the 1 ram is 4 before the LSIRF The switch must be positioned so it will activate after the front of 1 ram head clears the shear knives LSIRF LIMIT SWITCH 1 RAM FORWARD OPERATION FUNCTION POSITION The N O contacts will close when the 1 ram is fully forward To energize an input signal to the PLC when the 1 ram is forward See Electrical diagram and or Program The proximity sensor must be positioned so that it will actuate and stop the advancing of the 1 ram just as the face of the 1 ram head comes wit
31. e supply of fresh fluid covered tightly Use clean containers hoses and funnels when filling the reservoir Use common sense precautions to prevent entry of dirt into components that have been temporarily removed from the circuit Make sure that all clean out holes filler caps and breather cap filters on the reservoir are properly fastened Do not run system unless all normally provided filtration devices are in place Make certain that the fluid used in the system is of a type recommended by the manufacturers of the system of components Relative sizes of particles and comparison of dimensional units ADDITIONAL NOTES ON MAINTENANCE CYLINDERS Check the gland assemblies of all hydraulic rams and see that the packings gland rings and bushings are in good shape with no excessive leakage The molded type packing used in this equipment should not be subjected to mechanical pressure by the gland ring nor should it be permitted to move back and forth This packing functions on the self sealing principle and therefore the space in the gland bore should merely be long enough to hold the packing firmly in place RAM HEADS The wearing shoes under the ram heads should be watched and replaced promptly when they become worn This is important in order to keep the rams and cylin ders in proper alignment LINER PLATES The life of the liner plates will vary according to intensity of operation and type of material processed In some cases t
32. ecification sheet dAP rise time damping typical see specification sheet Repeat for switch 2 SP2 rP2 dS2 and OU2 E Pressure switch should be locked after set points have been adjusted see step A REPAIR REPLACE pressure switches For information on procedures refer to the Efector bulle tin There are no user serviceable parts in the switch III 15 LEVEL TEMPERATURE SWITCH The purpose of the level temperature switch is to monitor the level and temperature of the oil in the hydraulic tank PS 1 LSOLS OIL LEVEL LOW WARNING Set point 2000 20 in rP1 reset point 1800 18 in FUNCTION To signal that the oil level is getting low PS 2 L SOLL OIL LEVEL LOW SHUTDOWN Set point 1000 10 in rP2 reset point 920 9 2 in FUNCTION Shut down baler because of low oil PS 3 LSOE OIL TEMPERATURE WARNING Set point 135 F 57 C rP3 reset point 130 F 54 C FUNCTION To signal that the baler s oil temperature is rising 5 4 1 SOHT OIL HIGH TEMPERATURE SHUTDOWN Set point 155 F 68 C rP4 reset point 150 F 66 C FUNCTION Shut down baler because of high oil temperature SWITCH CONTROL method of actuation Sensor in the hydraulic fluid When the level or temperature reaches the set point the switch signals the PLC that the set point has been reached The set point is adjusted by push buttons on the front of the switch SETTING THE SWITCH
33. ee BALER SPECIFICATIONS in the IN TRODUCTION section OIL RECOMMENDATIONS Galland Henning uses the following brands of anti wear hydraulic oil to test the baler These brands of hydraulic oil meet all manufacturers specifications We recommend using these brands or their equivalent SUPPLIER BRAND Benzoil Petrolube 32 Mobile DTE 24 OIL TANK CAPACITY See BALER SPECIFICATIONS Section 1 OIL TEMPERATURE RANGE The following limits are based on an ambient air temperature range between 60 F and 90 F 16 C and 32 C Start 60 F 16 C Run 1OO F 140 F 38 60 C maximum NOTE If the running temperature should exceed the maximum limit given the system should be thoroughly inspected to determine the cause and the appropriate corrective action should be taken See TROUBLE SHOOTING TIPS in the Maintenance section for possible causes of excessive heat generation PNEUMATIC OIL RECOMMENDATIONS Hopper option To insure maximum performance valves should be supplied with clean lubricated air We recommend use of an airline filter and lubricator both of ample flow capacity installed as close as possible ahead of the valve and cylinder DO NOT USE oils having any detergent additives Following is a representative list of oil refiners and their particular brands SUPPLIER BRAND Cities Service Oil Co Citgo Pacemaker XD32 Exxon Teresstic 33 Gulf Oil Co Harmony 32 Shell Oil Co Tellus 32 Turbo 32 Mobile Oil Co Vectra Ligh
34. ere score marks replace rod or ram GENERAL MAINTENANCE INSTRUCTIONS FOR ALL GALLAND HENNING NOPAK INC BALERS EFFECTS OF DIRT IN HYDRAULIC SYSTEM Dirt is responsible for a majority of malfunctions and unsatisfactory performance Below is a partial list of what dirt can do to hydraulic components Pumps 1 Erodes wear plates 2 Causes sticking of vanes creating erratic actions 3 Cause the vanes to wear out the cam ring 4 Wears out rotor slots 5 Increases shaft journal and bearing wear 6 Increases gear wear with resultant inefficiency 7 Increases piston and sleeve wear with resultant Relief valves 1 Causes chatter 2 Accumulated dirt causes relief valve to fail safe pressure becomes erratic which affects function of entire system 3 Causes seat wear in relief valve Directional valves 1 Causes plugged orifices 2 Causes wear to spool and housing lands creating excess leakage 3 Dirt deposits cause spools to stick with resultant solenoid failure Sticking valves can cause excessive shock loads damaging hose piping fittings and other components Check valves 1 Dirt causes erosion of orifices changes flow characteristics Cylinders 1 Dirt causes excessive wear of A Cylinder rod B Packing C Bore of cylinder 2 Malfunction of cylinder cushions IV 16 GENERAL MAINTENANCE INSTRUCTIONS FOR ALL GALLAND HENNING NOPAK INC BALERS cont Fluid 1 Dirt acts as a catalyst breaks down m
35. faces FIXED DISPLACEMENT Refers to the displaced volume of a non adjustable pump VARIABLE DISPLACEMENT Refers to the displaced volume of an adjustable output pump LOAD ED amp UNLOAD ED Refers to an operating pumps output or work status condition and is governed by an unloading type valve located between the pumps outlet port and the first com ponent s of the working system Loaded If the pumps output is directed to the system for the purpose of performing work it is said to be loaded NOTE This term applies even if no work is actually performed for example The output may be loaded to a series of directional valves which in turn direct the output back to the tank Effective output pressure in this case is near zero NOTE This condition is also true when the output is directed to the tank as a relief condition which occurs when a loaded pumps output encounters work resistance in excess of a safe limit Effective output pressure in this case is equal to the maximum operating limit of the relief valves setting Unloaded If the pumps output is directed to the tank but not as a relief condition instead of the system the pump is said to be unloaded Effective output pressure in this case is near zero NOMINAL RATE Refers to the pump s rate of delivery at a specified R P M as represented by the pump s manufacturer OUTPUT The product of a working pump often measured in G P M gallons per min
36. g DANGER Personnel are extremely vulnerable to physical harm or death REFERENCES At the beginning of the hydraulics chapter and of the electrical chapter both in Section III are references to manual supplements pertaining to those subjects INSTALLATION BLUEPRINTS LIST HYDRAULIC DIAGRAM D 19569Y16 25 DL ELECTRICAL DIAGRAM D 19549E16 12 DL PRESS PARTS D 11795J16 31 DL PNEUMATIC DIAGRAM B 15685Y12 26 DL PUMPING UNIT ASSEMBLY D 19332J12 34 DL SIDE HOPPER ASSEMBLY D 183DC16 SAFETY GUARD ASSEMBLY D 19551116 36 DL BULK HOPPER ASSEMBLY N A WEIGH HOPPER ASSEMBLY D 18849J16 These as well as additional blueprints are supplied with the service manual kit OIL RECOMMENDATIONS Galland Henning uses the following brands of anti wear hydraulic oil to test the baler The general specification is ISO 11158 Type HM These brands of hydraulic oil meet all manufacturers specifications We recommend using these brands or their equivalent Follow manufacturer s instructions for safe handling of oil To eliminate the potential for a slip hazard all spills must be cleaned up immediately SUPPLIER BRAND Benzoil Petrolube 32 Mobile DTE 25 Conoco Phillips Megaflow AW 32 OIL TANK CAPACITY See baler specification sheet ABBREVIATIONS 16 DC The following is a list of abbreviations used throughout this manual and related drawings JAF 1 RAM Ist Compression Cylinder ALMOST FORWARD 1F 1 Ist Compression C
37. gh out the text Il Operation which contains operating instructions and process descriptions Machine Systems which contains independent descriptions of machine components and their functions IV Maintenance which provides general procedures for servicing trouble shooting and repairing V Parts which provides parts list parts identifications parts ordering and recommended spare parts VI Logic Program which is a print out of the computer program used to operate the machine VII Vendor Bulletins which are a collection of O E M bulletins providing in depth parts and service date on original equipment hardware VIII Drawings which are blueprints used in locating various sections of the machine for service repair and trouble shooting HOW TO USE THIS MANUAL DECALS Are identified and tabulated on the CONTROL DATA TABLE Use them to identify parts See the DECAL CHART for a pictorial view CODES Such as 22 DL refer to details which are tabulated Example 22 DL See Drawing List Table Linet22 On line 22 of the DRAWING LIST TABLE you will find the title and number of a drawing which applies to your machine OTHER NOTIFICATIONS Call your attention to details which must be observed where applicable NOTES xa Modify or supplement preceding descriptions WARNINGS Alert you to harmful procedures you must avoid CAUTIONS Urge you to consider the consequences before actin
38. h acts on a strain gage mechanism which signals the pressure switch When the pressure reaches the set point the switch signals the PLC that the set point has been reached The set point is adjusted by push buttons on the front of the switch SETTING THE PRESSURE SWITCH A Pressing both push buttons simultaneously and for 10 seconds locks or unlocks the set points for the switch B Pressing the Mode Enter push button steps the switch through its different functions When the desired parameter is reached pressing the Set push button will display current setting of that parameter If the switch is unlocked this value can be changed by pressing and holding the Set push button for 5 seconds the setting will flash and then start stepping through its range Releasing and pressing the button now will allow you to manually step the switch through the range When the desired setting is reached pressing the Mode Enter button sets the switch to the new setting and return the switch to the function display When the maximum setting is reached it will start over looping back to the lowest setting C When the switch is in the function mode if no switches are pushed for 5 seconds the switch will return to the operating mode III 14 PRESSURE SWITCHES cont D The switch functions are as follows SP1 switch 1 on set point switch 1 off set point 51 delay of switch 1 on set point OUT output of switch 1 see sp
39. he larger plates in the first compression part of the box have been known to last several years The smaller liner plates in the high pres sure end of the box take the heaviest wear and will need replacement more often The box liner plates are easily removed by first taking off the ramhead face plates and then fully retracting the 1 and 2 Rams LIMIT SWITCHES It may be necessary to reposition certain stroke limiting limit switches such as LSIR LS2R LSGC to prevent the cylinder s pistons from bottoming out and caus ing excessive system shock which may occur as components friction decreases and ram stopping distance increase TROUBLE SHOOTING PROCEDURE If you suspect the nature of the failure refer to the appropriate trouble shooting guide NOTE Use the same general procedures for pneumatics as for hydraulics If the cause of the failure is not evident it will be necessary to determine which one or more of the machine s components may be at fault This often requires a trial and error approach in which several possible causes are identified At times this can be a tedious process regardless of the complexity simplicity of the actual failure To avoid going in circles while investigating eliminating suspects use the following guide lines D Always describe the symptom as clearly and concisely as possible 2 Compare your description of the symptom or trouble to those given in the TROUBLE SHOOTING guides and in
40. hin 1 32 of 2 ram head II 20 LIMIT SWITCHES cont LS2RR LIMIT SWITCH 2 RAM RETRACTED BACK OPERATION The contacts will close when the 2 ram is fully retracted FUNCTION To energize an input signal to the PLC when the 2 ram head is retracted See Electrical Diagram and or Program POSITION The switch must be positioned so that it will actuate and stop reversing the 2 ram just as the face of the ram head leaves the baling chamber box LSMG LIMIT SWITCH MAIN GUARD DOOR CLOSED OPERATION This is a 5 wire safety switch that is wired in series with the E Stop switches The contacts are used to function as part of the safety interlock system and will shut the baler down if the door is opened When the door is open a message CECK E STOPS AND GUARD DOOR will be displayed on the HMI The contacts will close when the DOOR is closed FUNCTION See Electrical diagram and or program III 21 SECTION IV MAINTENANCE TABLE OF CONTENTS GENERAL GUIDELINES INSPECTION PROCEDURE OIL RECOMMENDATIONS FILTER MAINTENANCE ADDITIONAL NOTES ON MAINTENANCE TROUBLE SHOOTING PROCEDURE REPAIRS FACTORY ASSISTANCE TROUBLE SHOOTING TIPS NOISY PUMP PUMP NOT DELIVERING OIL OVERHEATING IN SYSTEM LOW PRESSURE IN SYSTEM EFFECTS OF DIRT IN HYDRAULIC SYSTEM PAGES IV IV 1 thru 4 V 5 amp 6 IV 7 IV 8 IV 9 IV 10 IV T IV 12 IV 15 IV 14 amp 15 IV 16 amp 17 MAINTENANCE This ma
41. i above the compen sator s setting SETTING Place keyed selector switch in the HAND mode and start pump 1 Loosen adjusting screw locking nut on RV1 and turn the adjust screw in several turns 2 Loosen the adjusting screw locking nut on the pump compensator screw 3 Advance the 2 cylinder forward against the gate and hold 4 Turn pump maximum pressure adjusting screw in until the system pressure is approximately 50 psi 3 4 Bar above the desired relief valve setting 5 Turn adjusting screw on until the desired setting is reached not exceeding 2600 psi 180 Bar and tighten locknut CAUTION Do not run pump in this mode for a long period of time because it will over load the motor 6 Adjust maximum pressure adjusting screw setting down to its operating setting 2400 psi 165 Bar max and tighten locknut 7 Retract the 2 cylinder The diverter valve acts to both block and flow of oil to tank and as a reduced pressure relief valve for the gate the cover lock when used and the side hopper optional circuits SETTING Place keyed selector switch in the HAND made start pump 1 Loosen adjusting screw locknut on the diverter valve 2 Manually shift the solenoid on the diverter valve and hold 3 Adjust the pressure to 1200 psi 83 Bar using the adjusting screw and tighten locknut 4 Release the solenoid on the diverter valve manually override a solenoid operated valve Locate the
42. k Feed Hopper and Side Hopper operation sections for details AUTOMATIC SEQUENCE OUTLINE of bale making stages Once the auto cycle is initiated the baler will perform each of the bale making stages automatically in the following order 1 Ist compression 1 RAM advances to end of forward stroke If the 1 Almost Forward Limit Switch LSTAF is reached before PS3 is actuated RAM may retract to allow more material to be dropped into the baler 2 2nd compression 42 RAM advances until PS1 is actuated 3 Bale made PS1 actuates when pressure reaches max 4 Decompression 1 amp 2 RAMS retract briefly 5 GATE opens 6 Bale eject 2 RAM advances to end of forward stroke PS2 is actuated 7 Cylinders return home in the following order a 2 RAMS retracts completely b GATE closes c 1 RAMS retracts completely 8 Cycle ends when 1 RAMS is fully retracted At this time the baler is said to be READY and CYCLED IN AUTO NOTE See Complete Automatic Sequence for detailed description of each stage listed above If the baler is not equipped with a BULK HOPPER than each subsequent cycle must be initiated by the operator During the automatic operation the normal function of the BULK FEED HOPPER is to automatically measure and dump when full one load of scrap per baling cycle into the baling chamber when the baler is ready and cycled in auto and to initiate new automatic baling cyc
43. le Thus the baler and bulk hopper together will operate in tandem automatically and continuously The 1st compression ram is set to make several gathering cycles before the 2nd compression ram is actuated Consult Galland Henning Nopak for further information To prevent the baling chamber from being over loaded and possibly jammed the electrical controls are designed so that the BULK FEED HOPPER will not perform its normal function see Hopper Operation for additional details if the continuous automatic cycling of the machine is interrupted For that reason it is always necessary to begin the initial automatic cycle by pressing the CYCLE START button After the baler has completed this initial auto cycle the BULK FEED HOPPER will resume its normal function The message BULK FEED HOPPER WAITING FOR MATERIAL will be displayed while the hopper is collecting material and the baler is READY and CYCLED IN AUTO IB AUTOMATIC MODE cont OPERATION IN AUTO MODE To operate in auto turn the MODE SELECTOR switch to the HAND position and start the pumps by pushing the MOTOR START button Then turn the mode selector to the AUTO mode Note Motor will not start if the GUARD DOOR is not closed START THE AUTO CYCLE by depressing the CYCLE START button WARNING Do not operate baler unattended in auto mode before BULK HOPPER and 1st Comp Recycle Counter is adjusted to produce desired bale size See NORMAL BALES
44. n adjusted see step A See switch operating instructions for more information III 17 LIMIT SWITCHES The purpose of the electronic electrical limit switch is to make or break an electrical signal in response to the presence or absence of a moving object at the location of the switch To accomplish this the switch actuator is placed in the path of the moving cam IDENTIFICATION Each switch on this machine is labeled and abbreviated after both the name and the position of the part it monitors EXAMPLE 1 LS 1 F FORWARD POSITION 1 RAM LIMIT SWITCH EXAMPLE 2 LS c CLOSED COVER LOCK LIMIT SWITCH To identify and or locate the limit switches on this machine refer to the List of Drawings and select the appropriate limit switch assembly drawing NOTE Because the limit switch is exposed to moving parts it is vulnerable to damage and misadjustment Consequently it immediately becomes a prime suspect in the event of a machine malfunction ADDITIONAL NOTE Wherever possible a switch s positioning should provide adequate deceleration of moving parts to stop the ram just as it reaches the end of its travel except LSIF 1 ram must always fully extend to make a clean no fin bale III 18 LIMIT SWITCHES cont Limit switches on this baler are either a mechanical type or a proximity sensor 1 The mechanic
45. n baler is ready and cycled in auto otherwise hopper will not dump to baler Hopper door will close after a 4 to1O second delay Auto cycle will begin when hopper door has closed NOTE An air supply of at least 80 psi 5 5 Bar must be maintained at the bulk hopper manifold inlet to keep the bulk hopper door closed Optional feature may not apply if not furnished by Galland Henning Nopak Il 11 SIDE HOPPER OPERATION The SIDE HOPPER optional is manually operated by a double acting ram It can be used when the baler is operating in either the manual mode or the auto mode provided the following conditions are met Baler is ready See Baler Ready Baler Not Ready Guard is closed LSSHGDC is actuated SIDE HOPPER UP The side hopper will rise only while the side hopper selector switch is on provided the above conditions are met SIDE HOPPER DOWN The side hopper can be lowered at any time provided pumps are operating by choosing hopper down on the selector switch To stop descent release the down selector SIDE HOPPER SPEED CONTROL See VALVES FLOW CONTROL START CYCLE To start the auto cycle after using the side hopper depress the CYCLE START push button Be sure that the PIVOT SCREEN is closed If the pivot screen is not closed the auto cycle will not begin NOTE The BULK HOPPER cannot dump to baler when the side hopper is in use nor until a subsequent auto cycle is completed To av
46. ng the compression stages of bale making It begins the moment the bale is made and progresses in the following order 1 AND 2 RAMS RETRACT BRIEFLY SOL IRR and SOL 2RR are energized then de energized for either a measure of time 42 RAM or distance 1 RAM This allows the rams to back away from the bale and relieves the forces exerted on the gate At this time the decompression stage is completed and the GATE will open NOTE Insufficient decompression will result in a side load on the Gate which prevents the opening of the gate GATE OPENS The GATE opens SOL GO is energized when the decompression stage is finished As the gate opens it leaves limit switch LSGC and rises to its fully open position actuating LSGO and de energizing SOL GO BLAE IS EJECTING message will display BALE EJECT STAGE This stage begins when the LSGO is actuated and BALE EJECTING message will be displayed The 42 Ram advances SOL 2RA is energized to the end of its stroke pushing the newly formed bale ahead of it through the open gate Once the 42 Ram has reached the end of its forward stroke hydraulic pressure will build rapidly in the blind end of the 2 cylinder When eject pressure is reached it will actuate Pressure Switch PS2 1000 psi 69 Bar and SOL 2RA is de energized CYCLE ENDING message will display The Bale Eject Stage ends at this time and the 1 and 2 Rams return home to their initial starting positions CYLINDERS
47. nto Maintenance Mode see Maintenance Mode in the Controls section Press the ALARM TEST key F6 The red beacon light will illuminate and the audible alarm will sound to indicate that the alarm system is working properly II 15 ABNORMAL BALES The baler is capable of consistently producing bales of uniform dimensions and density provided that both the quantity and characteristics of each load of scrap is uniform Irregularities in bale shapes usually occur in the form of a fin Bales with large fins are called chair bales Fins are most likely to form under the following conditions TOO MUCH CLEARANCE between the 1st compression side of 2 Ram head face plate and the face of the 1 Ramhead If this clearance cannot be reduced by repositioning limit switch LSIF then replace worn face plate s See Maintenance Liner Plates TOO MUCH CLEARANCE i e wear between the remaining edges of 2 Ramhead face plate and adjacent liner plates Replace worn parts as needed See Maintenance Liner Plates NOTE Small fins may be unavoidable if scrap is very light gauge STICKERS may cling to the 42 Ramhead as it retracts into the baling chamber after EJECT is complete especially if the bales are small or light in weight and finned DANGER DO NOT ATTEMPT TO EXTRACT A CLINGING BALE WHILE THE AUTO CYCLE IS IN PROGRESS INSTEAD TURN THE MODE SELECTOR SWITCH TO THE OFF POSITION AND CONSULT THE SAFETY PRECAUTIONS BE SURE TO
48. oid a possible hopper jam up Only use side hopper when bulk hopper is not full DANGER Be sure all personnel and equipment stand clear of the side hopper when it is in use Optional feature may not apply if not furnished by Galland Henning Nopak 1 12 ALARM SYSTEM MALFUNCTION ALERT A horn located in the control panel and a beacon mounted to the control panel will alert personnel to system malfunctions Whenever this horn sounds inspect the operator s console to determine the cause LOW OIL condition If the level of the hydraulic oil drops below the lowest visible level on the sight gauge mounted on the tank the malfunction alert will activate and the LOW OIL message will be displayed and hydraulic pump motor will be turned off OIL HIGH TEMPERATURE condition If the temperature of the oil exceeds 15O F 66 C a malfunction alert will activate the OIL HIGH TEMP message will be displayed and the hydraulic pump motor will be turned off The motor cannot be started again until the oil has cooled to the reset point of the temperature switch ALARM SILENCE The horn can be silenced immediately by pushing the ALARM SILENCE push button The message indicating the cause of the alarm and the beacon will remain on until the mode selector switch is put into HAND mode The alarm will sound again after approximately 2 minutes if not switched our of AUTO mode ALARM TESTING To test the alarm put the machine i
49. olecular structure causing gummy residue vanish 2 Dirt in the tank attracts additives and changes composition of the fluid System 1 Hydraulic system malfunctions due to dirt can result in A Serious damage to equipment B Safety hazards C Insufficient pressures KEEP HYDRAULIC SYSTEMS CLEAN IV 17 SECTION V REPAIR PARTS TABLE OF CONTENTS COMPLETE PARTS LIST BALER INSTALL ATI u ua pun sicco alas D 18862 J16 IST COMPRESSION TY CINDER riscopre 51715 2ND CONMPRESSION CYLINDER B 5172SK COVER CY CINDER creron na Susu maan Sasa C12119 X36 ELECTRICA EE E E D 19549 E16 GATE CYEINDER ASS anbe E E C 11764 X34 HYDRAULIC SCHEMATIQu uuu anun bike D 19569 Y16 LIMIT SWITCH ASS Y IST COMPRESSION C Yann ect usadas B 173 DC16 LIMIT SWITCH ASS Y 2ND COMPRESSION D 172 DC16 SEN ASS D 172 DC16 PRESS PR poorer Eo D 11793 J16 PRESS PLUMBING aan Sawka D 18867 J16 prr D 19332 J12 EC Declaration of Conformity We GALLAND HENNING NOPAK INC of 1025 South 40th Street West Milwaukee WI 53215 in accordance with the following Directive s 2004 108 EC EMC Directive 2006 42 EC Machinery Directive 2009 EN 602044 Safety of Machinery hereby declare that Equipment Dual Compression Heavy Duty Balers Model Numbers 10DCS 12DC 16DC 1
50. onsole may contain additional features for the operation of auxiliary systems Consult your Engineering Department for details MOTOR light when indicates the motor is running MANUALLY OPERATING THE CYLINDERS Operate the desired cylinder s by turning the appropriate selector switch on the OPERATOR S CONSOLE For safety purposes the action of each cylinder is restricted as follows 1 1 RAM cannot advance unless the 2 RAM is fully retracted 2 2 RAM cannot advance unless the GATE is fully closed or fully open 3 GATE cannot close unless the 2 RAM is fully retracted 4 BULK FEED HOPPER DOOR No Manual Control cannot open unless baler is in the auto mode and baler is ready and cycled in auto 5 SIDE HOPPER cannot operate unless 1 and 2 RAMS are retracted GATE is closed and BULK FEED HOPPER is not dumping to baler WARNING Pressing of material in the charging box by the 1 ram POSITIVELY MUST NOT be done unless gate is closed and the 2 RAM is fully retracted Serious damage to the baler could result if this precaution is not adhered to Optional feature may not apply if not furnished by Galland Henning Nopak l AUTOMATIC MODE THE AUTOMATIC MODE When the baler is in the AUTO mode all ram operating levers are inoperative with the exception of the BULK FEED HOPPER DOOR and the SIDE HOPPER which can be operated in the AUTO mode under special circumstances See Bul
51. ow control valves bulk hopper amp side hopper Monthly Pressure switch operating points Monthly Liner plates 6 Weekly Face plates 6 Weekly Gate guide amp wear bars for galling and or excessive wear Weekly Pin and or bushing walk cover amp side hopper Weekly Alarm system test Annually Divert to Rear test See WEIGH HOPPER OPERATION Weekly Cycle Time monitor See TIME CHART this section Monthly Indicator lights Replace when faulty As Needed Leaks 7 Weekly INSPECTION PROCEDURE cont FASTENERS Tighten the following items as indicated DESCRIPTION INTERVALS Cylinder tension rods Daily Cylinder rod eye Daily Hinge bearing blocks Daily Hinge pin set screw Monthly Hose amp pipe fittings 7 Monthly Liner amp face plates Monthly Ram head to ram rod 1 amp 2 Rams Monthly Press box joints side base amp end frames Monthly FOOTNOTES 1 Based on one 1 8 hour shift day 2 Use any weight clean waste oil if scrap has no oil or other lubricating residue 3 See FILTER MAINTENANCE and 28 VB 4 See HYDRAULIC OIL RECOMMENDATIONS this section 5 Remove switch from tank to test 6 Inspect for damage and or excessive wear Excessive wear of liner and face plates results in wedging of material between ram heads and liner plates See ABNORMAL BALES 7 Do not over tighten joints where persistent leaks develop Instead look for possible signs of joint fitting or other component failure To detec
52. ratures Measures should be taken by the Purchaser to avoid the harmful effects of occasional condensation ALTITUDE This equipment will operate correctly up to 3280 feet 1000m above mean sea level TRANSPORTATION AND STORAGE This equipment will withstand or has been protected against transportation and storage temperatures of 13 F 25 C and 131 F 55 and for short periods up to 158 F 709 It has been packaged to prevent damage from the effects of normal humidity vibration and shock FORESEEABLE MISUSE THIS EQUIPMENT IS NOT DESIGNED FOR COMPACTING CONTAINERS THAT CONTAIN FLAMMABLE TOXIC RADIOACTIVE OR BIOHAZARDOUS MATERIAL EXAMPLES OF ITEMS THAT SHOULD NOT BE BALED IN THIS MACHINE INCLUDE BUT NOT LIMITED TO AEROSOL CANS SOLVENT CANS MEDICAL WASTE MUNITIONS AND ELECTRICAL DEVICES 1 4 MANUAL MODE The MODE SELECTOR switch on the operator s console must be in the HAND position in order to operate the cylinders using the selector switches The only exceptions are The Bulk Feed Hopper Door auto only The Side Hopper See Bulk Feed Hopper or Side Hopper operations for details STARTING THE MOTOR The motor is started by the MOTOR START push button Motor will stop not start whenever the mode selector switch position is in or when the MOTOR STOP or EMERGENCY STOP buttons are activated NOTE Motor will stop not start if GUARD DOOR is opened not closed NOTE Your c
53. ressure Gate cylinder Force in tons Hopper cylinder side optional Cover Cylinder Force in tons Total H P of motors Hydraulic system Gallons requires for system System pressure G P M Floor area for baler Shipping weight 58 L x 24 W x 24 deep high side 16 cubic feet 42 L x 24 W 12 x 8 x variable 3504 to 1304 depending on material 208 to 80 60 seconds approximately 60 bales 8 63 436 PSI 30 bar 10 98 2045 PSI 141 bar 4 diameter 14 3 25 diameter 6 55 1 25 hp 1800 RPM 400V 3 50 HZ TEFC Class B insulation and greaseable ball bearings 150 2400 PSI 165 bar 54 17 0 14 0 15 500 Ibs DESCRIPTION CUSTOMER S DRAWING LIST CUSTOMER BAGPAK Polska CODE 1 DL 2 DL 3 DL 4 DL 5 DL 6 DL 7 DL 8 DL 9 DL 10 DL TI DL 12 DL 13 DL 14 DL 15 DL 16 DL 17 DL 18 DL 19 DL 20 DL 21 DL 22 DL 23 DL 24 DL 25 DL 26 DL 27 DL 28 DL 29 DL 30 DL 31 DL 32 DL 33 DL 54 DL 55 DL 6 DL 3 DL 38 DL 39 DL 40 DL 41 DL 42 DL 43 DL 44 DL 45 DL 46 DL 47 DL DESCRIPTION CONTROL LOGIC PROGRAM COVER CYLINDER COVER LIMIT SWITCHES ELECTRICAL DIAGRAM FIRST 150 COMPRESSION CYLINDER FIRST Ist COMPRESSION LIMIT SWITCHES FOUNDATION GATE SAFETY GUARD GATE CYLINDER GATE LIMIT SWITCHES GENERAL ARRANGEMENT HYDRAULIC SCHEMATIC PNEUMATIC DIAGRAM OPERATOR S CONSOLE PRESS PARTS LIST PUMPING UNIT LAYOUT PRESS
54. ressure increased the flow rate of the pump piston stroke is decreased automatically By reducing the flow as the pressure is increased less horsepower is required to drive the pump so a smaller motor can be used on the system while still reaching the required pressure and supplying a high flow rate of low pressure IIl 6 PUMP DATA This equipment uses a variable displacement axial piston pump referred to as ADJUSTMENTS The piston pump P1 has a horsepower limiter which is factory set and a pressure compensator which limits the maximum system pressure CONTROL Starting and stopping are performed by the operator using the STOP amp START push buttons on the operator s console OUTPUT CONTROL Refer to this subheading under the description of the Pl pump P1 pump Maximum operating pressure 3 000 psi 207 Bar The pressure compensator should be set to 2500 psi 172 Bar slightly higher then the pressure switch PS1 setting The pump also has a maximum limit stop which is left at full stroke FUNCTION P1 provides full fluid power to all hydraulic actuators OUTPUT CONTROL Plis loaded whenever any of the cylinders are in motion SAFETY PRESSURE RELIEF Over pressure protection for P1 is provided by RV1 NOTE For a description of Valve RV1 when and how it unloads see VALVES RELIEF Il 7 VALVES General Description Several different types of valves are used on this machine each
55. s will fail There fore system pressure limits must be established and maintained III 1 HYDRAULIC PRINCIPLES amp TERMINOLOGY cont DANGER PRESSURIZED HYDRAULIC FLUID ESCAPING FROM THE SYSTEM CAN CAUSE BODILY HARM DO NOT EXPOSE ANY BODILY PARTS TO JETTING OIL LEAKS NOTE For a more detailed description of pressure regulation look under VALVES UNLOADING RELIEF HYDRAULIC FLUID is of course necessary for the system to operate The type of fluid and its cleanliness is critical to the performance and the life of the system For more details see Oil Recommendations NOTE Further descriptions of these components Cidentification function control and adjustments are given on the following pages of this section PNEUMATIC PRINCIPLES Some baler options are operated by pneumatic air components For all practical purposes the principles are similar to hydraulic principles except that air is compressible and generally not suit able for operation at pressures in excess of 250 psi 17 bar This pneumatic system is designed to run properly at a range of 80 120 psi 5 5 8 2 bar The required air flow rate is 3 SCFM 120 psi 5 1m hour 8 bar III 2 START UP PROCEDURES FOR HYDRAULIC SYSTEMS WARNING To qualify for warranty eligibility all start up operating and maintenance procedures must be adhered to DANGER STARTING NEW AND UNFAMILIAR EQUIPMENT CAN PRESENT UNFORESEEN HAZARDS Be sure to observe the SAF
56. ssing can be terminated at any time by depressing any of these buttons Emergency Stop buttons are located on main control cabinet operators console and near the baler gate 2 HAND OFF AUTO Keyed selector must be in the HAND position 3 OPERATE MASTER RESET push button to engage and or restore control circuit power 4 Operate MOTOR START push button to start electric motor NOTE Auto mode controls will be operative only if the mode selector switch is in the AUTO position and the initial starting conditions are satisfied If auto operation is desired and the dataliner does not display the message ENGAGE AUTO MODE proceed to Section 11 6 Baler not Ready Monitor the position of each ram by observing the Dataliner CAUTION The hydraulic pump is directly coupled to the electric motor Whenever the motor is running the pumping units are active EVEN AT LOW PRESSURE THE HYDRAULIC CYLINDERS HAVE THE POTENTIAL TO DO GREAT BODILY HARM OBSERVE ALL SAFETY PRECAUTIONS WHENEVER THE PUMP ELECTRIC MOTOR IS IN OPERATION Optional feature may not apply if not furnished by Galland Henning Nopak GENERAL OPERATING CONDITIONS OPERATING TEMPERATURE This equipment will operate correctly in its intended ambient at a minimum between 41 F 5 C and 104 F 40 C RELATIVE HUMIDITY This equipment will operate correctly within an environment at 50 RH 104 F 40 C Higher RH may be allowed at lower tempe
57. switch positions see LIMIT SWITCHES in this section 7 Set pressure switches as follows NOTE For detailed instructions on setting pressure switches look under PRESSURE SWITCHES PS1 BALE MADE 2 400 psi 165 Bar maximum or a lessor pressure to reduce bale density PS2 BALE EJECTED 1100 psi 75 Bar PS3 RECYLE PRESSURE 900 psi 62 Bar 54 1 RAM FORWARD HOLD 1200 psi 83 Bar On new machines these components are pre set prior to shipping They should be inspected periodically to assure that proper limits are maintained Replacements are not pre set and must be adjusted during installation 11 4 PUMP TERMINOLOGY PUMP VOLUME The output volume of a pump under working conditions will differ disregarding efficiency factors from the nominal rate as specified by the O E M if the pump s actual speed differs from the nominal speed Actual Rate nominal rate x actual R P M nominal R P M BALANCED The term balanced characterizes the distribution of hydraulic forces at work on the revolving parts of the pump during operation This balance which is achieved by design permits high pressure operation while eliminating shaft and bearing side loads CAVITATION A condition that occurs in a pump when inlet suction causes the oil to become gas eous The sudden collapse of gaseous oil in the high pressure zone of the pump creates implo sive shock waves that pit the pump s critical internal sur
58. t Standard Oil of Ohio Chevron OC Turbine Oil 9 Texaco Regal R amp O 432 Union Oil Company Turbine Oil 4150 OIL MAINTENANCE In addition to taking all customary precautions to prevent oil contam ination see FILTER MAINTENANCE the user just also periodically analyze the oil to de tect contamination which will occur through normal wear and tear OIL CONTAMINATION The oil must be considered contaminated when it no longer meets the minimum requirements of the application and unsuitable for continued use IV 5 OIL RECOMMENDATIONS cont OIL ANALYSIS Consult your oil manufacturer s representative to establish test intervals and procedures The test should be made with an oil sample taken from the system at normal operating temperature and it should evaluate the following Viscosity pH Particle content Water content Air content NOTE Be sure to record test results for future reference OIL CHANGES must be made whenever the oil is unsuitable for continued use NOTE Be sure to inspect clean tank bottom to prevent residues or sediment from con taminating new oil FILTER MAINTENANCE Set up a filter maintenance schedule and follow it diligently Inspect filter elements that have been removed from the system for signs of failure which may indicate the need for shortening the service interval and the possibility of other system problems Do not return to the system any fluid which has leaked out Always keep th
59. t piston by pass allow oil to cool Then conduct the following test Run ram to end of stroke Manually override directional valve to maintain pressure Examine cylinder discharge line for sudden temperature rise 8 Cushion decelerate rod action at end of stroke may need readjustment after cover repairs are performed See NOPAK Cylinder Maintenance VENDOR SECTION 9 See NOPAK bulletins VENDOR SECTION if piston packings need replacement 10 To tighten ram head to ram rod remove ram face plate NOTE See appropriate section for details also see reference tables DL Drawing List VB Vender Bulletin General Specifications INSPECTION PROCEDURE cont AUTO CYCLE TIME CHART Use this chart as reference when monitoring your machine s performance Substantial variation exhibited by your machine will indicate abnormal performance NOTE This chart represents empty cycle times The durations of Ist amp 2nd compression stages will increase variably with the size and characteristics of the load being baled OPERATIONAL STAGES SPLIT TOTAL Cycle start 00 00 to Cover closed 92 02 to 1 Ram fully forward with regen 08 10 to bale made 23 to decompression finished amp gate opened 05 28 to eject finished 06 34 to 1 Ram fully retracted 09 43 to 42 Ram fully retracted 08 51 to gate closed O3 54 to cover opened fully 06 60 Cycle ends For additional information on 16DC specifications s
60. this time Baler Ready and Cycled in Auto by depressing the BALER CYCLE START push button The AUTO START BALER ONLINE pushbutton must be depressed after the cycle to have Bulk Hopper initiated cycles CAUTION If the bulk hopper which is full when the automatic cycle ends the hopper will immediately empty into the baler and start the next baler cycle NOTE Operation of the side hopper optional will cancel the Cycled in Auto latch mentioned above Subsequent baler cycles must be initiated by the operator 1 10 WEIGH HOPPER OPERATION The BULK HOPPER optional is an electrically controlled and pneumatically operated gravity box Its purpose is to accumulate and automatically unload a fixed quantity of scrap With the BULK HOPPER in operation the quantity of Scrap is determined by a high level sensor switch LSHF that detects the level of scrap in the hopper HOPPER FULL Once the hopper is full it will cylce in the following sequence The HOPPER DOOR will open when solenoid SOL WHO is energized via LSHF hopper full limit switch photo eye The hopper door will remain open approximately five 5 seconds after which time the solenoid hopper will de energize and the hopper door will close The automatic press cycle will begin with the 1 RAM extending as soon as the hopper door is closed and LSHDC hopper door closed limit switch is actuated OPEN HOPPER DOOR via push button only in auto mode whe
61. uble Replace worn and broken parts per manufacturers recommendations IV 14 TROUBLE SHOOTING TIPS cont LOW PRESSURE IN SYSTEM AND ERRATIC ACTION CAUSE INCORRECT CONTROL VALVE SETTING SLUGGISHNESS WHEN A MACHINE IS FIRST STARTED 4 WAY VALVE NOT SHIFTING FIN ON BALE OR CHAIR TYPE BALES BENT RAMS OR CYLINDER RODS EXCESSIVE LEAKS ON ROD END OF CYLINDER IV 15 ACTION 1 Check control valve piston and cylinders Replace worn parts 2 If open center directional control valves are set at neutral position oil will return to reservoir 1 Oil too thick at starting temperature Run Temperature Run pump for a few minutes oil may thin out If oil does not thin out replace oil with lower pour point lighter viscosity Under severe conditions immersion heaters may be required 1 Electrical trouble on solenoid operated valves shift solenoid by hand If valve operates call electrician to check circuit 2 Pilot pressure too low on pilot pressure operated valves Check manufacturer s recommendations 3 Main valve spool sticking disassemble valve Clean up spool and bore with crocus cloth if necessary to free spool 1 Excessive material in charging box 2 Check for excessive wear on liner plates or shoes 1 Baling with gate open or not fully closed 2 All rams not fully retracted when baling cycle begin 1 Worn rod end packing replace with new packing 2 Check for score marks on rod Too sev
62. ulk Hopper or Side Hopper and is followed by compressing and ejecting see Automatic Sequence Outline NOTE Some equipment described in the following sections is optional and may not be part of your system DISCLAIMERS Nonconforming Use Galland Henning shall not be responsible for any damage which may occur as a result of noncompliance with all safety precautions or non standard applications Alterations to baler Galland Henning shall not be responsible for any damage which may occur as a result of modifications regardless of their nature which have been made to the baler without written authorization from our factory PROCEDURES SAFETY PRECAUTIONS INITIAL START UP Before the initial start up is performed the user is advised to first verify start up readiness by completing the pre start up check list and then becoming thoroughly acquainted with this manual and the accompanying drawings Particular atten tion should be paid to the following articles of this manual Safety Precautions Hydraulic System Starting Procedures Manual Operation Automatic Operation Bulk Feed Hopper Operation Side Hopper Operation Il 1 PROCEDURES SAFETY PRECAUTIONS cont SAFETY PRECAUTIONS Any and all personnel working with or performing service to this machine must observe the following safety procedures This machine should be operated only by individuals who have been thoroughly instructed in its proper use
63. unless specified otherwise 20 30 weight machine oil for the remainder DESCRIPTION INTERVALS Air lubricator See PNEUMATIC OILS this section Weekly 1st compression limit switch trolley Weekly Gate guide bars 2 As Needed Gate wear bars 2 As Needed Motor bushing Biannually Motor couplings Biannually Press box liner plates 2 As Needed Side hopper hinge As Needed NOTE See appropriate section for details also see FOOTNOTES of Guidelines IV 1 INSPECTION PROCEDURE cont HYDRAULIC OIL Maintaining an adequate level of hydraulic oil that is properly filtered is critical to the life of hydraulic components DESCRIPTION INTERVALS Oil filter inspect Tells All 3 Daily Oil filter clean replace 3 As Needed Oil level inspect 4 Daily Oil temperature monitor 4 Daily Test low oil level alarm 5 Annually Analyze oil chemically for contamination Annually CLEAN UP Keep the following areas free of debris for the protection of personnel and equipment Walkways around machine Daily Limit switches and cams Daily Pinch and shear points Daily Exposed cylinder rods Daily Degrease machine periodically Do not allow oil and residue to accumulate INSPECT and or ADJUST the following using procedures given in the appropriate compo nent description in other sections of this manual Pneumatic relay timers Biannually Cylinder packings 7 9 Weekly Limit switches cams actuators amp mounting plates Monthly Fl
64. ute SHAFT END The coupling or shaft end of a pump VANE PUMP Refers to a pump which utilizes blades vanes to propel the hydraulic oil The vanes are driven rotationally by the pump shaft and a radial slotted hub rotor which contains them Each slot in the rotor is occupied by a vane and permits the tip of that vane to follow the contour of the eccentric inner surface of the stationary cam ring The shaft rotator vane and cam ring assembly is sandwiched by a ported wear plate and a ported pressure plate III 5 PUMP TERMINOLOGY cont In the simplest sense a vane type pump operates like a motor driven non stop revolving door which pulls in the flow on one side low or inlet pressure side while pushing out the flow on the other side high or outlet pressure side The pulling and pushing of the pump is creat ed as the revolving parts of the pump vanes sweep through regions of increasing and decreas ing volume formed by the spinning rotor and the stationary cam ring and the ported plates which contain them PISTON PUMP Axial variable displacement This pump uses reciprocating pistons moving in a rotating block to draw in fluid at the inlet and push fluid out at the outlet A variable swash plate mounted on a yoke allows the stroke of the pistons to be varied from zero stroke for a no flow con dition to its maximum stroke for full flow The pump is pressure compensated which means that as the output p
65. vestigate course s suggested by the closest matching description 3 Devise a method to test the suspect component Use the appropriate component description s in this text to devise tests and analyze results and determine if the component is ok or not ok 4 Disassemble and inspect repair or simply replace components which exhibit faulty behavior 5 Repeat steps 1 thru 4 until normal operation is achieved NOTE One effective method to accomplish step is to swap suspect parts with like parts If the symptom migrates with the swap the suspect part is proven defective TO IDENTIFY PARTS See Parts IDENTIFICATION Section V REPAIRS Timely and conscientious repairs overhauls are necessary to prevent compounding of component failures which are likely to occur if the machine is allows to run partially dis abled To avoid this correct component failure immediately Refer to the appropriate VENDOR BULLETIN when detailed instructions are needed Also see PARTS IDENTIFICA TION WARNING Be sure to observe all safety procedures as outlined in the OPERATION SEC TION FACTORY ASSISTANCE If you would like factory assistance don t hesitate to call our Service Department Be sure to mention the model number and serial number of your machine See the title page of this manual IV 10 TROUBLE SHOOTING TIPS NOISY PUMP CAUSE AIR LEAKING INTO SYSTEM AIR BUBBLES IN INTAKE OIL CAVITATION AT PUMP INLET WOR
66. ylinder FORWARD 1R 1 RAM Ist Compression Cylinder RETRACTED 2R 2 RAM 2nd Compression Cylinder RETRACTED AVE AVERAGE BM BALE MADE CCW COUNTERCLOCKWISE CD CONTROL DATA TABLE COMP COMPRESSION CR CONTROL RELAY CS CYCLE START CW CLOCKWISE CYL CYLINDER D DIVERTER DC DUAL COMPRESSION DECOMP DECOMPRESSION DL DRAWING LIST TABLE DP DIVERTER POSITION EJ EJECT GC GATE CLOSED GO GATE OPEN GPM or gpm GALLONS PER MINUTE WHD HOPPER DOWN HDC BULK HOPPER DOOR CLOSED WHU HOPPER UP LS LIMIT SWITCH MAN MANUAL P PUMP PC PROGRAMMABLE CONTROLLER PS PRESSURE SWITCH PSI or psi POUNDS PER SQUARE INCH R REVERSE RPM REVOLUTIONS PER MINUTE RV RELIEF VALVE SOL SOLENOID TCR CONTROL RELAY TIMED V VALVE VB VENDOR BULLETIN TABLE WS WEIGH SCALE NOTE two or more abbreviations are frequently used in conjunction to form a decal EXAMPLE LSIF LIMIT SWITCH 1 RAM FORWARD SPECIFICATIONS DUAL COMPRESSION AUTOMATIC BRIQUETTING PRESS MODEL 16DC A SPECIFICATIONS Al A2 A3 4 A5 A6 7 Charging Box Dimensions Charging Box Volume Charging Box Clear Opening Briquette size Briquette weight steel aluminum Complete operational cycle Cycles per hour A8 1st compression cylinder A9 A10 All Al2 13 14 15 16 EI Piston diameter Force in tons Ramhead face pressure 2nd compression cylinder Piston diameter Force in tons Ramhead face p

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